Versatile surface heating cartridge for cooking appliance

ABSTRACT

A versatile surface cooking cartridge for use in an appliance includes a lower container portion to which is attached a lid member. A first heating element is arranged in the lower container portion and a second heating element is carried by and extends along a lower surface of the lid member. One of a replaceable rack or cooking plate can be positioned in the lower container portion, above the first heating element, to enable food items to be cooked by heat generated by either or both of the first and second heating elements. The cooking plate preferably has a sloped surface leading to a recess trap for collecting byproducts generated during cooking upon the plate. The cooking plate can define a grilling plate, a griddle plate, or a reversible, combination grilling/griddle plate.

The present application constitutes a continuation-in-part of U.S.patent application Ser. No. 09/690,849 filed Oct. 18, 2000, now U.S.Pat. No. 6,271,504.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention pertains to the art of cooking appliances and,more particularly, to a replaceable surface heating cartridge for use inperforming multiple cooking operations.

2. Discussion of the Prior Art

In the art of cooking, it is commonly known to utilize surface heatingelements for various cooking operations, including boiling, grilling,frying, steaming and the like, depending on the particular type of panor other cooking container utilized. Such surface heating elements,whether of the gas or electric type, are typically incorporated as partof a cooktop which is either mounted within a cutout portion of akitchen countertop or formed as part of a range. Most often, the surfaceheating elements are intended to only be replaced if damaged. That is,it is common to design a cooktop or range for use with a particular setof heating elements, with generally two front heating elements and tworear heating elements which can be individually, selectively controlled.

The desire to provide more versatility in the type of cooking operationswhich can be readily performed with the surface heating elements hasalso been recognized. Therefore, certain cooking appliance models arespecifically designed to be used with replaceable cartridges. Forinstance, it is known to form a cooking surface with various wells, witheach well being able to selectively receive either a pair ofindividually controllable surface heating elements or a single, enlargedgrilling unit. Such an arrangement enhances the versatility of theoverall cooking appliance.

Although considered to have its advantages, such a multi-purpose heatingsystem does require the consumer to make a change between variouscooking elements when it is desired to carry out certain differentcooking operations. Based on the above, there still exists a need in theart of cooking appliances for a more versatile cooking cartridge whichcan be initially supplied for a cooktop or range, or which can beutilized as a replacement cartridge. In any event, there is a need for aversatile cartridge which defines multiple cooking surfaces and can beused to perform a variety of cooking operations, preferably inclusive ofcertain cooking operations typically dedicated to an oven, without theneed to change the cartridge.

SUMMARY OF THE INVENTION

The present invention is directed to a versatile surface cookingcartridge which can be effectively used to perform a variety of cookingoperations, preferably including baking, broiling, grilling and frying.In accordance with a preferred embodiment of the invention, a cookingcartridge includes a lower container portion to which is pivotallyattached a lid member. Within the lower container portion is arranged afirst heating element. A second heating element is carried by andextends along a lower surface of the lid member. Separate controls areprovided for selectively operating the first and second heatingelements, either individually or simultaneously. A rack, grill plate orgriddle plate can be selectively positioned in the lower containerportion, above the first heating element.

With this arrangement, the cartridge can function to cook food placedupon the rack, grill plate or griddle plate, with the first heatingelement being operated alone, the lid closed and both the first andsecond heating elements activated, or the lid closed and just the secondheating element being activated. In addition to or in the alternative ofperforming a cooking operation within the lower container portion, theupper surface of the lid member can also define a further cookingsurface, such as a smooth, flat cooking surface, upon which one or moreadditional cooking operations can be performed upon heating the surfacethrough the operation of at least the second heating element. Therefore,the upper surface of the lid member can be directly used in performingfrying operations, or simply as a heating surface upon which a pan orthe like can be placed for even further cooking modes.

In any event, the cooking cartridge of the invention represents aversatile and convenient arrangement which can be readily provided withnewly produced cooking appliances or supplied as a replacement cartridgeuseable in existing cooking appliances designed for use with removablecartridges. Additional objects, features and advantages of the inventionwill become more readily apparent from the following detaileddescription of preferred embodiments, when taken in conjunction with thedrawings wherein like reference numerals refer to corresponding parts inthe several views.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a cooking appliance incorporating areplaceable cooking cartridge constructed in accordance with the presentinvention;

FIG. 2 is a perspective view of the cooking cartridge of FIG. 1 in aclosed condition;

FIG. 3 is a perspective view of the cooking cartridge in an opencondition;

FIG. 4 is a cross-sectional side elevational view of the cookingcartridge shown in FIGS. 1-3 with a rack positioned therein;

FIG. 5 is a perspective view of the cooking cartridge, similar to thatof FIG. 3, having a grilling plate positioned therein; and

FIG. 6 is a cross-sectional side elevational view of the cookingcartridge shown in FIG. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With initial reference to FIG. 1, a cooking appliance, generallyindicated at 2, is shown to take the form of a range. Cooking appliance2 includes a cabinet 6 including opposing side panels 8, a cooktop 9, arear panel (not shown) and a front panel 11. An upper portion of frontpanel 11 defines a face 12 that includes a plurality of controls as willbe more fully described below. Arranged below upper front face 12 is anoven door 16 having a handle 18 and a window 20. In a manner known inthe art, door 16 can be pivoted to access an interior oven cavity (notseparately labeled) of cooking appliance 2. Also, as shown, cookingappliance 2 includes a lower drawer 24 for use in storing pans and thelike.

In the embodiment illustrated, upper front face 12 is provided with acentral oven control section 28 that includes a display 29 and varioussets of control buttons 31-33. Although not considered part of thepresent invention, for sake completeness, control button set 31 ispreferably utilized to establish a desired mode of operation for theoven of cooking appliance 2, control button set 32 represents a numericpad including a cancel button, and control button set 33 representsprogram buttons for establishing desired cook times, clock settings andthe like. In addition, upper front face 12 is provided with a pluralityof element control knobs 37-40. In this embodiment, element controlknobs 37 and 38 are utilized to control the operation of upper heatingelements 43 and 44 respectively. In the most preferred embodiment, upperheating elements 43 and 44 are integrated into a first cartridge 46which is adapted to be selectively placed within a first opening 47formed in cooktop 9. As will be detailed more fully below, elementcontrol knobs 39 and 40 are adapted to control the operation of a secondcartridge 49 that is received within a second opening 50 (also see FIG.4) formed in cooktop 9.

Also illustrated in accordance with the preferred embodiment is adowndraft grill 52 that is arranged between first and second cartridges46 and 49. In a manner generally known in the art, downdraft grill 52 isused in combination with a blower element to exhaust smoke or the likewhen cooking on cooktop 9. The overall downdraft system can becontrolled through one of the buttons in central oven control section 28or automatically whenever any one of element control knobs 37-40 areplaced in an activated state. In general, with the exception of secondcartridge 49 and its manner of operation, the construction and operationof cooking appliance 2 is known in the art. Therefore, additionaldetails of this construction or operation will not be provided here.Instead, reference will now be made specifically to FIG. 2-4 indescribing a preferred construction and operation of second cartridge49.

As shown, second cartridge 49 is defined by a lower container portion 60that includes a base 63, as well as front, rear and opposing sidewalls64-67. Walls 64-67 terminate, at an uppermost portion thereof, in aperipheral rim 70. Spaced from base 63, each opposing sidewall 66 and 67is preferably formed with an inwardly projecting, fore-to-aft extendingrail, one of which is shown at 73 on sidewall 66. The opposing rail 73is preferably provided at the same height so as to extend in acommensurate horizontal plane.

Second cartridge 49 also preferably includes a cover or a lid member 80having a front end portion 83 and a rear end portion 84. Rear endportion 84 is hinged at 86 to lower container portion 60 such that lidmember 80 can pivot between a raised position shown in FIG. 3 whereinaccess to within lower container portion 60 is permitted, and a loweredor closed position generally shown in FIG. 2. As best shown in FIG. 3,lid member 80 preferably includes a down-turned peripheral edge 88 whichprojects away from an inner surface 90. Lid member 80 also includes anouter surface 92 which, in the preferred embodiment, is substantiallysmooth. In the most preferred embodiment, both lower container portion60 and lid member 80 are formed of metal and, most preferably, steel.Also, as shown in these figures, lid member 80 preferably has athickness which is in the order of 2-4 times that of any of walls 64-67of lower container portion 60. In order to aid in shifting of lid member80 between its raised and lowered positions, a handle 96 is provided atfront end portion 83. In general, handle 96 is generally shown to beconstituted by an angled member, however, a wide range of handlearrangements could be readily utilized.

Second cartridge 49 also includes first and second heating elements 105and 106, each of which is preferably constituted by an electric,sheathed, resistance-type heating element. As shown, first heatingelement 105 is positioned within lower container portion 60, verticallybetween base 63 and rails 73. More specifically, first heating element105 extends in a generally serpentine path within lower containerportion 60 and terminates in a first set of electrical connecting prongs109 and 110 which project out through front wall 64 of lower containerportion 60. Adjacent first set of electrical connecting prongs 109 and110 is a second set of connecting prongs 113 and 114 which areassociated with second electric heating element 106. Second electricheating element 106 is attached to lid member 80 directly adjacent toinner surface 90. More specifically, as generally shown in FIGS. 3 and4, second electric heating element 106 is preferably surrounded by innersurface 90 and down-turned peripheral edge 88 adjacent hinge 86. Secondelectric heating element 106 terminates in a third set of electricalconnecting prongs 115, 116. As will be discussed more fully below, thethird set of electrical connecting prongs 115 and 116 are electricallyinterconnected to the second set of prongs 113 and 114.

As shown in FIG. 4, lower container portion 60 is preferably defined byinner and outer housings 119 and 120 having a channel 122 therebetween.The upper periphery of channel 122 is closed off by means of a ledge 125formed as part of inner housing 119. It is upon ledge 125 thatdown-turned peripheral edge 88 of lid member 80 preferably rests uponclosing of lid member 80. In any event, inner and outer housings 119 and120 are preferably welded or otherwise fixedly secured about ledge 125in order to form lower container portion 60. The third set of electricalconnecting prongs 115, 116 are electrically interconnected to the secondset of connecting prongs 113, 114 by means of respective wires 134 whichare routed through channel 122 between the respective prongs 113-116.

It is known in the art to provide replaceable cartridges in bothelectric and gas cooking appliances. For example, it would be possibleto replace first cartridge 46 with a grilling cartridge in accordancewith prior proposals. Second cartridge 49, constructed in accordancewith the present invention, is therefore presented as an alternative,replaceable cartridge. However, second cartridge 49 is constructed tooperate in a versatile manner to enable various cooking operations to beperformed therewith. These various cooking operations will be detailedmore fully below. At this point, it should be noted that, in order toreceive second cartridge 49 or another replaceable cartridge constructedin a manner known in the art, cooking appliance 2 preferably includesvarious electrical junctions, one of which is indicated at 139 in FIG.4, located within a recessed well 142. Therefore, with thisconstruction, second cartridge 49 can be inserted within well 142, withthe first and second sets of electrical connecting prongs 109, 110 and113, 114 creating an electrical circuit through first and secondelectric heating elements 105 and 106. As indicated above, theactivation of the first and second electric heating elements 105 and 106are selectively controlled through control knobs 39 and 40 respectively.With this arrangement, first and second heating elements 105 and 106 canbe individually or simultaneously operated at varying settings in amanner generally corresponding to conventional surface heating elementssuch as those represented by elements 43 and 44.

When second cartridge 49 is mounted within recessed well 142, firstelectric heating element 105 is preferably spaced above base 63 andbelow rails 73 through the use of a plurality of support legs 145. In asimilar manner, second electric heating element 106 is spaced belowinner surface 90 or lid member 80 by support legs 146. In general, it isknown in the art of ovens to utilize electric resistance-type, sheathedheating elements having wire support legs attached thereto. In thepresent embodiment, support legs 145 and 146 are simply also welded orotherwise secured to base 63 and lid member 80 respectively.

As shown in the embodiment of FIG. 4, during use, a rack 150 can besupported across rails 73. Rack 150 can be used to support various fooditems, such as patties as indicated at 152 in FIG. 4, for cooking thesame. In accordance with the preferred construction of second cartridge49, a wide range of cooking operations can be performed on cooktop 9.For example, with lid member 80 closed and first electric heatingelement 105 activated, a baking or grilling operation can be performedwithin lower container portion 60. A broiling operation could also beselectively performed by activated second electric heating element 106instead of first electric heating element 105. A combination cookingarrangement can be provided by activating both first and second heatingelements 105 and 106. In addition, since outer surface 92 of lid memberalso defines a cooking surface, outer surface 92 can be heated by theactivation of second electric heating element 106 such that objects canbe directly fried upon lid member 80. In a further alternative, pans orthe like can be placed directly on outer surface 92 of lid member 80 foreven further cooking modes. Again, cartridge 49 can be selectivelyreplaced such that it represents an additional alternative available toa consumer. In this manner, second cartridge 49 can be provided with anewly produced cooking appliance 2 or supplied as a replacementcartridge for existing cooking appliances designed for use with removalcartridges.

The subject matter described to this point is encompassed by U.S. patentapplication Ser. No. 09/690,849 which is incorporated herein byreference. The present invention presents the added advantage ofutilizing second cartridge 49 with one or more additional cookingsurfaces in place of rack 150. With specific reference to the embodimentof FIGS. 5 and 6, there is shown a potential variation wherein rack 150has been replaced with a grilling plate 175. As shown, grilling plate175 includes an upper surface 177 provided with a plurality of higher orraised portions 180 which are spaced by lower, trough portions 182. Atleast trough portions 182 preferably slope forward and lead to afrontal, recessed trap 185 for collecting grease and/or other cookingbyproducts generated during use of second cartridge 49. Most preferably,the entire upper surface 177 of grilling plate 175 slopes towards trap185 as shown in FIG. 6 given that rail 73 extends substantiallyhorizontally.

The embodiment of FIGS. 5 and 6 also depicts the potential of having anadditional plate 200 carried by lid member 80. In accordance with thisaspect of the invention, plate 200 would also include various crests andtroughs (not separately labeled) which could have a configurationsimilar to that with respect to raised portions 180 and trough portions182 or which could be closer together in the manner depicted in FIG. 5.In any event, although only a small section of plate 200 is shown inFIG. 5 in order to enable the illustration of heating element 106 andfurther structure of lid member 80, it should be recognized that plate200 would preferably extend entirely across lid member 80. In accordancewith a most preferred embodiment of the invention, various clips, one ofwhich is indicated at 202, are provided to removeably retain plate 200in a desired position, while allowing plate 200 to be removed forcleaning or replacing. Furthermore, as clearly illustrated in FIG. 6,plate 200 preferably includes various recessed or grooved sections 205within which is arranged respective portions of heating element 106.With this overall arrangement, heat generated by heating element 106 ismore efficiently conveyed to plate 200. This overall arrangement enablespatties 152 or other foods being cooked to be sandwiched between plates175 and 200, as clearly shown in FIG. 6, to enhance the even cookingthereof.

In accordance with this overall invention, second cartridge 49 can beused to cook food items within lower container portion 60 with aselected one of various cooking surfaces. That is, in the embodimentsdepicted, the consumer can selectively position at least one of rack 150or grilling plate 175 within lower container portion 60. Although notshown, it is further contemplated that still further plate arrangementscould be provided. For instance, another cooking plate having asubstantially smooth upper surface could be provided to define a griddlesurface within lower container portion 60. As shown, a lower surface 190of grilling plate 175 can actually be substantially smooth such thatgrilling plate 175 can be reversible so as to constitute a combinationgrilling/griddle plate. Such a smooth griddle plate arrangement could beprovided to supplement or replace the smooth outer surface 92 of lidmember 80. In the latter case, insulation would be provided between lidmember 80 and second heating element 106 which extends along innersurface 90. In any event, the inclusion of one or more removable cookingplates, interchangeable with or in place of rack 150, simply aids indefining an even more versatile, overall cooking system. Incorporatingstructure to enhance the collection and subsequent cleaning/disposal ofcooking byproducts, including the provisions of raised and loweredsurface portions on each grilling plate 175, 200 and trap 185, isconsidered to be an even further advantageous feature of the presentinvention. Most preferably, each of cooking plates 175 and 200 isprovided with a non-stick coating to enhance cleanability.

Although described with respect to preferred embodiments of the presentinvention, it should be readily apparent that various changes and/ormodifications can be made to the invention without departing from thespirit thereof. For example, although lid member 80 is preferably hingedat rear end portion 84, other hinge locations or mounting arrangementscould be utilized. In addition, the particular location and constructionof the electrical connection for cartridge 49 could also greatly varyaccording to the invention. Furthermore, although upper surface 177 ofgrilling plate 175 has been disclosed as sloping forward toward recessedtrap 185, trap 185 could be located along any side or even in aninterior portion of grilling plate 175. Of course, upper surface 177and/or trough portions 182 would be correspondingly sloped. Equally,plate 175 could be formed with an opening which leads to a byproductcollection container arranged below plate 175 or container portion 60could actually be placed in communication with an overall greasecollection system for appliance 2. Finally, it should be recognized thatthe particular shape and/or configuration of either of plates 175 or 200could be readily varied. In general, the invention is only intended tobe limited by the scope of the following claims.

We claim:
 1. In an appliance including a cooktop provided with at leastone removable surface heating unit, a replaceable, integrated heatingcartridge comprising: a lower container portion adapted to bepositioned, at least in part, within an opening formed in the cooktop; afirst heating element extending within the lower container portion; aremovable food support member positioned in the lower container portionabove the first heating element; a lid member having an upper surfaceand a lower surface, said lid member being movable, relative to thelower container portion, between a lowered position wherein the lidmember substantially covers the lower container portion, and a raisedposition wherein an interior of the lower container portion is exposed;a second heating element carried by and extending along the lowersurface of the lid member; and at least one control member forselectively activating and deactivating each of the first and secondheating elements, wherein at least one of the first and second heatingelements can be activated for selectively cooking food placed on thesupport member within the lower container portion.
 2. The heatingcartridge according to claim 1, wherein the removable food supportmember constitutes a plate.
 3. The heating cartridge according to claim2, wherein said plate includes an upper surface, with at least a portionof said upper surface being sloped.
 4. The heating cartridge accordingto claim 3, further comprising: a recessed trap for collectingbyproducts generated during cooking upon said plate, wherein the portionof said upper surface slopes towards the recessed trap.
 5. The heatingcartridge according to claim 4, wherein the portion of the upper surfacedefines troughs, with the troughs leading to the recess trap.
 6. Theheating cartridge according to claim 2, wherein said plate includesupper and lower surfaces, with one of said upper and lower surfacesbeing substantially smooth and another of said upper and lower surfacesincluding varying height portions.
 7. The heating cartridge according toclaim 2, further comprising: at least a pair of opposing rails providedin the lower container portion, said plate being removably supported onthe rails.
 8. The heating cartridge according to claim 2, wherein theplate is reversible, having opposing surface portions definingdifferently configured cooking surfaces.
 9. The heating cartridgeaccording to claim 2, further comprising: a second plate attached to thelid member for movement with the lid member between the raised andlowered positions, said second plate covering at least a portion of thesecond heating element.
 10. The heating cartridge according to claim 9,wherein the second plate is readily removably attached to the lidmember.
 11. In an appliance including a cooktop, a heating cartridgecomprising: a lower container portion adapted to be removablypositioned, at least in part, within an opening formed in the cooktop; afirst heating element extending within the lower container portion; afood support member supported in the lower container portion above thefirst heating element; a lid member having an upper surface and a lowersurface, said lid member being movable, relative to the lower containerportion, between a lowered position wherein the lid member substantiallycovers the first heating element and the food support member, and araised position wherein the food support member is exposed; a secondheating element extending above the food support member when the lidmember assumes the lowered position; and at least one control member forselectively activating and deactivating the first and second heatingelements, wherein at least one of the first and second heating elementscan be activated for selectively cooking food placed on the supportmember within the lower container portion.
 12. The heating cartridgeaccording to claim 11, wherein the food support member is removablysupported within the lower container portion.
 13. The heating cartridgeaccording to claim 12, wherein the food support member constitutes aplate.
 14. The heating cartridge according to claim 13, wherein saidplate includes an upper surface, with at least a portion of said uppersurface being sloped.
 15. The heating cartridge according to claim 14,further comprising: a recessed trap for collecting byproducts generatedduring cooking upon said plate, wherein the portion of said uppersurface slopes towards the recessed trap.
 16. The heating cartridgeaccording to claim 15, wherein the portion of the upper surface definestroughs, with the troughs leading to the recess trap.
 17. The heatingcartridge according to claim 13, wherein said plate includes upper andlower surfaces, with one of said upper and lower surfaces beingsubstantially smooth and another of said upper and lower surfacesincluding varying height portions.
 18. The heating cartridge accordingto claim 13, further comprising: at least a pair of opposing railsprovided in the lower container portion, said plate being removablysupported on the rails.
 19. The heating cartridge according to claim 13,wherein the plate is reversible, having opposing surface portionsdefining differently configured cooking surfaces.
 20. The heatingcartridge according to claim 13, further comprising: a second plateattached to the lid member for movement with the lid member between theraised and lowered positions, said second plate covering at least aportion of the second heating element.